Brunel University of London
About
BCAST (Brunel Centre for Advanced Solidification Technology) is a world-renowned research centre transforming solidification and casting. Established in 2002, it is one of the largest and most impactful groups globally, advancing light metals research and industrial innovation. BCAST integrates pioneering researchwith cutting-edge technology development and industrial implementation, revolutionising the automotive, aerospace, and manufacturing sectors. Its Industrial Services division provides advanced solutions in inspection, recycling, and lifecycle management, driving sustainability and efficiency. Committed to shaping the future, BCAST trains the next generation of metallurgists, delivering transformative innovations and sustainable practices to create a lasting impact on industry and the planet.
At the heart of BCAST's success lies its comprehensive approach to innovation. The centre spans over 10,000 m² on Brunel University London's campus, housing more than £48M in large-scale metal processing facilities and £10M in advanced analytical and testing equipment. This exceptional infrastructure, combined with world-class metallurgical expertise, enables BCAST to master the complete innovation value chain—from fundamental discovery through to industrial deployment.
The centre's Industrial Services division exemplifies this practical approach, offering sophisticated solutions in materials testing, inspection, recycling, and lifecycle management. Equipped with advanced testing and characterisation technologies, this division helps manufacturers develop lighter, stronger, and more sustainable components while ensuring the highest standards of material integrity.
BCAST's innovation ecosystem includes several specialized facilities. The Advanced Metal Casting Centre (AMCC) and Advanced Metal Processing Centre (AMPC) serve as crucial bridges between laboratory research and industrial implementation, significantly reducing the time and cost of commercializing new alloys and processing technologies. The recently established £16M Future Metallurgy Centre (FMC) pushes boundaries further with its state-of-the-art characterization facilities, featuring advanced atomic-scale electron microscopy, 3D atom probe technology, comprehensive X-ray capabilities, and sophisticated thermo-mechanical processing simulation tools.
Through close collaboration with industrial partners, BCAST transforms fundamental research into practical solutions, creating a lasting positive impact on both industry and environmental sustainability. This integration of pioneering research, technological innovation, and industrial implementation positions BCAST as a unique national asset and global leader in transforming the future of metal processing and manufacturing.
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What does you company offer ?
The Brunel Centre for Advanced Solidification Technology (BCAST) is a world-leading research center specialising in solidification, casting, and processing of light metals such as aluminum and magnesium. BCAST focuses on developing sustainable, high-performance materials for automotive, aerospace, and other industrial applications. Its expertise includes alloy design, advanced metal processing, recycling, and lifecycle management to support a circular economy and low-carbon manufacturing. BCAST operates state-of-the-art facilities, including the Advanced Metal Casting Centre (AMCC) and Advanced Metal Processing Centre (AMPC), bridging the gap between research and industrial-scale implementation. BCAST’s expertise aligns with BATT4EU’s goals in the following ways: 1. Sustainable & Recyclable Lightweight Materials for Batteries BCAST develops advanced aluminum and magnesium alloys that can be used in battery casings, cooling systems, and structural components to improve lightweighting and energy efficiency. These materials help reduce the overall weight of EV batteries, improving vehicle range and performance. 2. Circular Economy & Recycling of Battery Materials BCAST’s high-shear melt conditioning (HSMC) technology enables cleaner and more efficient recycling of aluminum and magnesium, which are critical for battery enclosures. Expertise in closed-loop recycling ensures minimal waste and maximized material reuse, reducing the carbon footprint of battery production. 3. Advanced Manufacturing & Process Optimization BCAST’s work in thermo-mechanical processing, high-pressure die casting, and semi-solid processing contributes to the development of durable and high-performance battery components. Advanced casting techniques can be applied to improve battery cooling plates, enclosures, and busbars, which are essential for battery efficiency and longevity. 4. Structural Health Monitoring & Non-Destructive Testing (NDT) BCAST’s Industrial Services division offers material testing, inspection, and lifecycle management, ensuring that battery components meet stringent safety and durability standards. Use of X-ray analysis, CT scanning, and AI-driven monitoring to detect defects and optimize battery material integrity.
What are you looking for?
BCAST is seeking collaboration with partners who can contribute expertise in battery material development, advanced recycling technologies, sustainable manufacturing, and energy storage solutions. Specifically, BCAST is looking for industry and research partners with capabilities in battery-grade aluminum and magnesium applications, circular economy solutions for end-of-life battery materials, and scalable manufacturing processes for lightweight battery enclosures and thermal management systems. Additionally, partners with expertise in AI-driven materials optimization, non-destructive testing, and structural health monitoring can support BCAST’s goal of ensuring high-performance, durable, and recyclable battery components. Collaboration will focus on accelerating BATT4EU-aligned innovations in next-generation battery materials and processes.